Wiring harness, vehicle component, mold, mold system and method for manufacturing the wiring harness

ABSTRACT

A wiring harness ( 1010 ), a motor vehicle component ( 1000 ), a mold ( 15 ) for manufacturing a wiring harness ( 1010 ), a mold system ( 10 ) and a method for manufacturing the wiring harness ( 1010 ), the wiring harness ( 1010 ) comprising at least one bunch ( 1020 ) of at least two cables ( 1025 ) and a sheath ( 1030 ), at least some sections of the bunch ( 1020 ) of cables being embedded in the sheath ( 1030 ).

CROSS-REFERENCE TO RELATED APPLICATION

This application is a Divisional Application of the U.S. applicationSer. No. 16/099,913, filed on Nov. 8, 2018, which is the National Stageof International Application No. PCT/EP2017/061054, filed on May 9,2017, which claims priority from German Patent Application No. 10 2016108 522.7, filed on May 9, 2016.

BACKGROUND Field of the Invention

The invention relates to a wiring harness, to a vehicle component of amotor vehicle, to a mold for manufacturing a wiring harness, to a moldsystem and to a method for manufacturing the wiring harness.

Background

Wiring harnesses with individual cables for connecting differentcomponents in a motor vehicle are known. In this context, the cables arestrung on a mounting board and wound in a winding tape. The wiringharness is produced substantially in a manual way, and therefore theproduction of the wiring harness is particularly expensive.

It is the object of the invention to provide an improved wiring harness,an improved vehicle component, an improved mold, an improved mold systemand an improved method for manufacturing a wiring harness of this kind.

SUMMARY OF THE INVENTION

This object is achieved by means of a wiring harness for a motor vehicleas described and claimed. Advantageous embodiments are indicated in thedependent claims.

It was recognized that an improved wiring harness for a motor vehiclecan be provided if the wiring harness has a cable bundle with at leasttwo cables and an envelope. At least some section or sections of thecable bundle is/are embedded in the envelope. In this way, it ispossible to dispense with laborious winding of the cable bundle.Moreover, the envelope ensures that the wiring harness can be bent andguided around tight radii particularly easily. Moreover, the individualcables of the cable bundle are protected by the envelope.

In another embodiment, the envelope has an indicating element on theoutside, wherein the indicating element is routed parallel to the cablebundle in order to indicate a position of the cable bundle, wherein theindicating element extends substantially over the entire longitudinalextent of the envelope, wherein at least some section or sections of theindicating element is/are configured to correspond to a geometricalconfiguration of a holding device of a mold. The first bulge is a simplemeans of indicating the alignment of the cable bundle in the envelope,thus enabling the wiring harness to be laid particularly quickly in themotor vehicle.

In another embodiment, the indicating element has a first bulge, whereinthe first bulge is of bead-type configuration, and/or wherein theindicating element has a notch on the outside of the envelope. Thisenables the cable bundle to be found particularly quickly in theenvelope when repairing the wiring harness.

In another embodiment, the first bulge extends substantially over anentire longitudinal extent of the envelope.

In another embodiment, the wiring harness has a first fastening element.At least some section or sections of the first fastening element is/areembedded in the envelope. The first fastening element is configured tohold at least one of the cables of the cable bundle in a predefinedposition. In this way, heating of the wiring harness can be fixed in adefined way, thus reliably avoiding even local overheating of the wiringharness. It is thereby possible to avoid irreversible damage to thewiring harness in a simple way.

In another embodiment, the wiring harness has a second fasteningelement. The second fastening element has a first section, which isembedded in the envelope. The second fastening element furthermore has asecond section, which is configured to engage in a vehicle component ofthe motor vehicle in order to fasten the wiring harness on the vehiclecomponent.

In another embodiment, the envelope has a first layer, a secand layerand preferably a third layer, wherein the cable bundle is embedded inthe first layer, wherein the first layer comprises a first material, andthe second layer comprises a second material, wherein the secondmaterial preferably has a different elasticity from, preferably a higherelasticity than, the first material, wherein the second layer ispreferably of rectangular configuration or has a rib structure, wherein,on a side facing the first layer, the second layer preferably has asurface provided with a predefined surface structure, wherein, on a sidefacing away from the first layer, the second layer is preferably of flatconfiguration, wherein the third layer is preferably arranged on a sideof the second layer which faces away from the first layer, wherein thethird layer comprises at least one material, wherein the third materialcomprises an adhesive and/or has a third elasticity, which is differentfrom, preferably lower than, the first and/or the second elasticity.This enables the second layer to serve as a protection for the cablebundle, thus avoiding possible damage to the cable bundle, e.g. by sharpedges of a body of the vehicle.

In another embodiment, the first layer is of slimmer configuration in adirection transverse to the cable bundle than the second layer, whereinthe first layer is configured to engage in a recess in a vehiclecomponent, wherein the first layer preferably has a trapezoidal crosssection and the second layer preferably has a substantially rectangularcross section.

In another embodiment, the envelope has a second bulge, wherein thewiring harness can be passed through a feedthrough opening in a vehiclecomponent, wherein the second bulge extends with a slope relative to alongitudinal extent of the cable bundle, wherein the second bulge isconfigured to form a, preferably fluidtight, separation between twospaces in the vehicle component, at least in some section or sections,wherein the second bulge has a bulge contour, wherein the second bulgeis configured to press the bulge contour against a feedthrough openingcontour of the feedthrough opening in order to provide substantiallyfluidtight separation between the spaces.

In another embodiment, the envelope has a second bulge, wherein thesecond bulge extends with a slope relative to a longitudinal extent ofthe cable bundle, wherein the second bulge is configured to form a,preferably fluidtight, separation between two spaces in the vehiclecomponent, at least in some section or sections, wherein the secondbulge has a bulge contour, wherein the second bulge is configured topress the bulge contour against a recess contour of a recess in avehicle component in order to provide a frictional connection betweenthe recess and the second bulge and to fasten the wiring harnessfrictionally in the recess. This enables the wiring harness to thefastened in the motor vehicle in a particularly simple way.

In another embodiment, the envelope has a first envelope section and asecond envelope section. The first envelope section has a firsttransverse extent with respect to a first direction of longitudinalextent of the first envelope section. The second envelope section has asecond transverse extent with respect to a second longitudinal extent ofthe second envelope section. The first transverse extent is greater thanthe second transverse extent.

The envelope has a transitional section. The transitional section isarranged between the first envelope section and the second envelopesection. The first envelope section has a first lateral surface and thesecond envelope section has a second lateral surface. The transitionalsection has a transitional surface, which has a slope relative to thefirst lateral surface and the second lateral surface. The slope has anangle, wherein the angle has a value which is less than 45°, inparticular less than 30°, in particular less than 20°, in particularless than 15°, in particular less than 10°.

However, the object is also achieved by a vehicle component of a motorvehicle.

It has been recognized that an improved vehicle component for a motorvehicle can be provided if the vehicle component has a structure havingat least one recess with a recess contour and has a wiring harnessdescribed above, wherein at least the second bulge engages in therecess, wherein the second bulge is arranged at least partially underprestress, preferably under compression, in the recess, and the secondbulge presses the bulge contour against the recess contour and providesa frictional connection between the wiring harness and the vehiclecomponent. It is thereby possible to make particularly efficient use ofan available installation space within the vehicle component of themotor vehicle. Moreover, rattling of the wiring harness against astructure of the vehicle component is avoided by means of thesurface-to-surface contact with the structure.

In another embodiment, the wiring harness is arranged in the recess,wherein the structure has a surface adjoining the recess, wherein thesurface and an upper side are of stepless configuration, and the surfaceand the upper side preferably extend in a common plane. In this way, thewiring harness can be laid in the vehicle with a particularly smallinstallation space requirement and, at the same time, fixing of thewiring harness can be ensured in a simple manner. Furthermore, catchingof other components of the motor vehicle on the wiring harness whenmounted on the structure is avoided.

However, the object is also achieved by means of a mold formanufacturing the above-described wiring harness. Advantageousembodiments are indicated below.

It has been recognized that an improved mold for manufacturing a wiringharness can be provided if the mold has a wall and an opening. The walldelimits a mold cavity, at least laterally. The mold cavity adjoins theopening at the top.

By virtue of the upwardly open mold, the cables can be laid particularlyeasily during the manufacture of the wiring harness without having to bepulled around pins. As a result, the wiring harness can be manufacturedparticularly quickly. Moreover, it is also possible for the cables to belaid automatically by means of a robot, and therefore manufacturingcosts are further reduced by automation.

In another embodiment, the mold has a holding device. The holding deviceis arranged on the wall and covers the opening, at least in some sectionor sections, wherein the holding device is of plate-type and/orbrush-type configuration, wherein the holding device comprises amaterial which is capable of reversible elastic deformation, and theholding device can be bent reversibly through at least 70°, preferablythrough 90°, preferably into the mold cavity. This avoids a situationwhere the cables laid in the mold cavity can accidentally slip out.Floating of the cables in the mold cavity during the foaming of theenvelope is also avoided.

It is particularly advantageous here if the wall has a wall base,wherein the holding device is arranged parallel to the wall base, atleast in some section or sections.

In another embodiment, the wall has a first wall section and a secondwall section. The first wall section is arranged opposite the secondwall section, wherein the holding device comprises a first holdingelement and a second holding element, wherein the first holding elementis arranged on the first wall section, and the second holding element isarranged on the second wall section, wherein the first holding elementand the second holding element each end with a free end over the openingand close the mold cavity, at least in some section or sections, whereinthe first wall section and/or the second wall section are/is preferablyprovided with an undulating profile, at least in some section orsections.

In another embodiment, the free ends of the holding elements arearranged spaced apart, and/or the holding elements are arranged in anoverlapping manner over the opening.

In another embodiment, the first wall section has a first wall regionand a second wall region, wherein the first wall region is arrangedsubstantially parallel to the second wall section, wherein the secondwall region extends in a manner offset from the first wall region in adirection away from the second wall section, with the result that themold cavity has a widened portion, wherein the second wall region isconfigured to correspond to the first bulge contour and/or to the secondbulge contour.

In another embodiment, an aperture is provided in the wall, wherein theaperture is configured as a through opening and is arranged in a wallbottom of the mold, wherein the wall bottom delimits the mold cavity atthe bottom, wherein the aperture is configured to accommodate at least asection of the first and/or second fastening element of the wiringharness, and/or wherein an ejector for removing the wiring harness fromthe mold is configured to reach through the aperture, wherein theaperture is preferably configured to correspond to the ejector. As aresult, the wiring harness can be removed from the mold particularlyeasily and by machine.

In another embodiment, an aperture is provided in the wall, wherein theaperture is configured to accommodate at least a section of the firstand/or the second fastening element of the wiring harness.

In another embodiment, the wall has a first wall surface section, asecond wall surface section and a wall surface transitional section,wherein the first wall surface section is preferably arranged lower thanthe second wall surface section, wherein the wall surface transitionalsection is arranged between the first wall surface section and thesecond wall surface section, wherein the wall surface transitionalsection is arranged with a slope relative to the first wall surfacesection and the second wall surface section, wherein the slopepreferably has an angle, wherein the angle has a value which is lessthan 45°, in particular less than 30°, in particular less than 20°, inparticular less than 15°, in particular less than 10°. This avoidscracking in the wiring harness at the transition between the first wallenveloping section and the second wall enveloping section.

In another embodiment, the first wall surface section and the secondwall surface section are arranged in two planes arranged parallel to oneanother.

In another embodiment, the holding device is configured so as to followthe wall and to be interrupted in some section or sections and/or to becontinuous.

In another embodiment, the holding device comprises silicone as thematerial. In addition or as an alternative, the wall comprises at leastone of the following materials: polytetrafluoride, polyoxymethylene.

These materials have a particularly low surface tension as compared withthe material of the envelope, thus ensuring reliable demolding of thewiring harness after the curing of the envelope. In particular, it isalso ensured, through the use of the materials for the wall, that alarge number of wiring harnesses can be manufactured with the moldwithout further cleaning or reprocessing steps to produce the originalmold being required in addition.

In another embodiment, the wall has a wall surface which faces the moldcavity, wherein the wall surface is laser-polished, at least in somesection or sections. By means of laser polishing, any scoring that maybe present, due, in particular, to the mold cavity being milled into themold, is mitigated, with the result that the molding and removal of thewiring harness from the mold is reliably ensured.

In another embodiment, the wall is profiled in an undulating and/orrib-shaped and/or planar manner, at least in some section or sections.This enables the wiring harness to be matched optimally to thegeometrical boundary conditions in the vehicle in a simple manner.

In another embodiment, a sealing element is arranged at one longitudinalend of the wall in order at least partially to prevent emergence of theenvelope from the mold cavity.

In another embodiment, the mold has a first mold part and a second moldpart. The first mold part has a first engagement element at onelongitudinal end. The second mold part has a socket configured tocorrespond to the first engagement element at a longitudinal end of thesecond mold part which faces the longitudinal end of the first moldpart. The first engagement element engages in the first socket andconnects the first mold part positively to the second mold part, whereinthe engagement element and the socket are configured in such a way inrelation to one another that removal in the longitudinal direction isblocked by the engagement of the engagement element in the socket,wherein the engagement element and the first mold part are preferably ofintegral and materially unitary configuration. This enables the mold tobe expanded or adapted particularly easily.

In another embodiment, the mold is configured to be fastened on amounting board of a mold system.

However, the object is also achieved by a mold system.

It has been recognized that an improved mold system can be provided ifthe mold system comprises a mold and a mounting board, wherein the moldis configured as described above, wherein, on a side facing the mountingboard, the mold has a further engagement element and, on a side facingthe mold, the mounting board has at least one grid having a plurality offurther sockets, or wherein, on a side facing the mounting board themold has a further socket and, on a side facing the mold, the mountingboard has a grid having a plurality of further engagement elements,wherein the further engagement element and the further socket arearranged in a manner corresponding to one another, wherein the furtherengagement element engages in one of the further sockets and connectsthe mounting board positively and in a reversibly detachable manner tothe mold, wherein the other further sockets of the grid remain free orwherein one of the further engagement elements engages in the furthersocket and connects the mounting board positively and in a reversiblydetachable manner to the mold, wherein the other further engagementelements of the grid remain free, wherein the further engagement elementis preferably of integral and materially unitary configuration with themold or with the mounting board.

As a result, the mold can be mounted particularly quickly on themounting board, or the mold system can be adapted particularly quicklyto a different wiring harness to be manufactured.

However, the object is also achieved by a method. Advantageousembodiments are indicated below.

According to the invention, it has been recognized that an improvedmethod for manufacturing a wiring harness configured as described abovecan be provided if a mold configured as described above is provided,wherein at least one cable of the cable bundle is laid in the moldcavity, wherein, as the cable is laid in the mold cavity, the holdingdevice is deformed and opened reversibly in such a way out of a closedposition in a first region by means of a means, preferably being bentinto the mold cavity or bent away from the mold cavity, that the openingis free in the first region, at least in some section or sections, andthe holding device remains in the closed position in a second region andcloses the opening, wherein the cable is laid in the mold cavity throughthe first region, wherein the means is moved along the mold cavity,wherein, after the removal of the means, the holding device relaxes andcloses the mold cavity again, wherein at least one material of theenvelope is introduced into the mold cavity, wherein the material flowsin the direction of gravity in a processing time of the material of theenvelope and, in doing so, encloses the cables of the cable bundle, atleast in some section or sections.

In another embodiment, as the cable is laid in the first region, thefirst holding element and the second holding element are bent apartreversibly out of the closed position by the means, preferably beingbent out into the mold cavity or away from the mold cavity or being bentin the longitudinal direction of the mold cavity, wherein, after theremoval of the means, the holding elements bend back into the closedposition and close the opening again.

In another embodiment, after the introduction of the material of theenvelope into the mold cavity, a cover is placed on the holding device,wherein the cover at least partially blocks bending open of the holdingdevice on a side facing away from the mold cavity.

In another embodiment, the material of the envelope is first of allintroduced into the mold cavity above the first wall surface sectionand, during a subsequent time period, is introduced into the mold cavityabove the second wall surface section and into the mold cavity above thewall surface transitional section.

In another embodiment, the material of the envelope is applied in amanner fluctuating in an undulating fashion in the transverse directionwith respect to the cable bundle between the first wall section and thesecond wall section. In this way, reliable embedding of the cable bundlein the surrounding wall is ensured.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention is explained in greater detail below by means of figures,in which:

FIG. 1A shows a detail of a cross section through a vehicle component ofa motor vehicle according to a first embodiment;

FIG. 1B shows a detail of a plan view of the vehicle component shown inFIG. 1A;

FIG. 2 shows a section through a vehicle component according to a secondembodiment;

FIG. 3A shows a detail of a cross section through a vehicle component ofthe motor vehicle according to a third embodiment;

FIGS. 3B to 3D each show a detail of a cross section of a respectivedevelopment of the vehicle component shown in FIG. 3A;

FIG. 3E shows a longitudinal section through a development of thevehicle component shown in FIG. 3A;

FIG. 4A shows a detail of a cross section through a vehicle component ofthe motor vehicle according to a fourth embodiment;

FIG. 4B shows a detail of a cross section through a development of thevehicle component shown in FIG. 4A;

FIG. 5 shows a longitudinal section through a wiring harness;

FIG. 6 shows a perspective view of a wiring harness in anotherembodiment;

FIG. 7 shows a perspective view of a wiring harness in anotherembodiment;

FIG. 8 shows a perspective view of a wiring harness in anotherembodiment;

FIG. 9A shows a perspective view of a mold system for manufacturing atleast one wiring harness shown in FIGS. 1 to 8;

FIG. 9B shows a plan view of the mold system shown in FIG. 9A;

FIG. 10 shows a perspective view of the first mold part of the moldshown in FIG. 9A and FIG. 9B according to a first embodiment;

FIG. 11A shows a section through the mold shown in FIG. 10, along asection plane A-A shown in FIG. 10;

FIG. 11B shows a section through a variant of the mold shown in FIG. 10,along the section plane A-A shown in FIG. 10;

FIG. 12 shows a section through a first mold part according to a secondembodiment along the section plane A-A shown in FIG. 10;

FIG. 13 shows a perspective view of a first mold part according to athird embodiment;

FIG. 14 shows a detail of a perspective view of the mold;

FIG. 15 shows a perspective view of a development of the mold shown inFIGS. 9A to 14;

FIG. 16 shows a perspective view of a development of the mold shown inFIGS. 9A to 15;

FIG. 17 shows a detail of a perspective view of a development of themold shown in FIG. 16;

FIG. 18 shows a perspective view of the first mold part according to afourth embodiment;

FIG. 19 shows a perspective view of the mold with the mold part shown inFIG. 18;

FIG. 20 shows a perspective illustration of the wall in a development;

FIG. 21 shows a perspective illustration of the wall in a variant of theembodiment shown in FIG. 20;

FIG. 22 shows a perspective view of the mold in another embodiment;

FIG. 23 shows a longitudinal section through the mold in anotherembodiment;

FIG. 24 shows a perspective view of a mold in another embodiment;

FIG. 25 shows a perspective view of a mold in another embodiment;

FIG. 26 shows a perspective view of a mold in another embodiment;

FIG. 27 shows a perspective view of the first fastening elementaccording to a first embodiment;

FIG. 28 shows a perspective view of a first fastening element accordingto a second embodiment;

FIG. 29 shows a perspective illustration of a first fastening elementaccording to a third embodiment;

FIG. 30 shows a perspective view of a first fastening element accordingto a fourth embodiment;

FIG. 31 shows a perspective illustration of a second fastening element;

FIG. 32 shows a perspective view of the second fastening elementaccording to a second embodiment;

FIG. 33 shows a flow diagram of a method for manufacturing the wiringharness;

FIG. 34 shows a plan view of the mold system during a third method step;and

FIG. 35 shows a section along a section plane D-D shown in FIG. 34.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1A shows a detail of a cross section through a vehicle component1000 of a motor vehicle according to a first embodiment. The vehiclecomponent 1000 has a structure 1005 and a wiring harness 1010. Thestructure 1005 can be a body, a deep-drawn part, a roof lining, a doorpanel, an intermediate panel, a soundproofing bulkhead or a cockpit, forexample.

The structure 1005 can be manufactured from sheet metal or plastic, forexample. However, the structure 1005 can also be a plastic structure, acarpet or similar. The structure 1005 has a bearing surface 1015. Thebearing surface 1015 faces the wiring harness 1010.

The wiring harness 1010 has a cable bundle 1020 comprising a pluralityof cables 1025. The cables 1025 serve to transmit electric signals or anelectric current between two points. The cables 1025 are arranged so asto run approximately in the same direction to one another. In thisarrangement, a connecting system for connecting the wiring harness 1010electrically to another electric device can be provided at therespective end of the wiring harness 1010. The cables 1025 of the cablebundle 1020 are embedded in an envelope 1030 of the wiring harness 1010.On the outside, the envelope 1030 has a lateral surface 1035 having anenvelope contour.

The envelope 1030 preferably comprises at least one of the followingmaterials: polyurethane, silicone, foam, closed-cell foam, open-cellfoam, silicone foam, polyurethane foam. The wiring harness 1010 restsagainst the bearing surface 1015 by means of the lateral surface 1035.In this arrangement, an adhesive layer can additionally be providedbetween the bearing surface 1015 and the lateral surface 1035 in orderto connect the wiring harness 1010 materially to the structure 1005.

In this arrangement, there is freedom of choice as regards the crosssection of the envelope 1030, and it should preferably be chosen tocorrespond to the geometrical configuration of the bearing surface 1015.At the same time, it is particularly advantageous if the bearing contourand the envelope contour are identical in some section or sections, thusensuring particularly good surface-to-surface contact between the wiringharness 1010 and the structure 1005.

It is particularly advantageous if the envelope 1030 comprises anindicating element 1038. The indicating element 1038 comprises a firstbulge 1036, advantageously on an upper side 1037 of the wiring harness1010. The first bulge 1036 projects above the upper side 1037. The firstbulge 1036 is preferably of bead-type configuration and preferablyextends parallel to the cable bundle 1020, at least in some section orsections. The indicating element 1038 can be arranged centrally withrespect to a maximum first transverse extent b₁. It is thereby possiblein a simple manner to indicate the route of the cables 1025 of the cablebundle 1020. The indicating element 1038 can furthermore be used toindicate a predefined side for the insertion of the wiring harness 1010into the structure 1005, thus enabling the wiring harness 1010 to bemounted particularly quickly during the assembly of the motor vehicle.In addition or as an alternative, it is also conceivable for theindicating element 1038 to comprise a notch 1040 in the upper side 1037(illustrated in dashed lines in FIG. 1A). The notch 1040 can serve toindicate a particular type of wiring harness 1010, for example.

FIG. 1B shows a detail of a plan view of the vehicle component 1000shown in FIG. 1A.

The indicating element 1038 extends substantially over the entirelongitudinal extent of the wiring harness 1010. This enables aninsertion position of the cable bundle 1020 in the envelope 1030 to bedetermined in a particularly simple manner. This is advantageousparticularly when the envelope 1030 is of particularly thickconfiguration and it is not possible to either feel or see the cablebundle 1025 in the envelope.

FIG. 2 shows a section through a vehicle component 1000 according to asecond embodiment. The vehicle component 1000 is configured in such away as to be substantially identical to the vehicle component 1000 shownin FIG. 1A and FIG. 1B. The structure 1005 has a first space 1100 and asecond space 1105. A partition wall 1110 is provided between the firstspace 1100 and the second space 1105. The partition wall 1110 has anopening 1115. The wiring harness 1010 is passed through the opening1115.

The wiring harness 1010 is configured in such a way as to besubstantially identical to the wiring harness 1010 illustrated in FIG.1A and FIG. 1B. In addition, the envelope 1030 of the wiring harness1010 has a second bulge 1120. The second bulge 1120 extends transverselyto a longitudinal extent of the cable bundle 1020. At least in theregion of the second bulge 1120, the envelope 1030 advantageouslycomprises a flexible material. The second bulge 1120 has a bulge contour1121. The second bulge 1120 is arranged in the opening 1115 and fillsthe opening 1115. The second bulge 1120 is preferably pressed/compressedinto the opening 1115. As a resuit, the second bulge 1120 presses thebulge contour 1121 circumferentially against an opening contour 1122 ofthe opening 1115 and seals off the first space 1100 fluidically from thesecond space. Furthermore, noise transmission between the first space1100 and the second space 1105 by the second bulge 1120 is therebyavoided. It is particularly advantageous here if the second bulge 1120is arranged so as to encircle the cable bundle 1020. A particularlyadvantageous possibility here is for the second bulge 1120 to be oftriangular configuration in cross section. It is thereby possible todispense with the use of a grommet in the opening 1115.

FIG. 3A shows a detail of a cross section through a vehicle component1000 of the motor vehicle according to a third embodiment. The vehiclecomponent is of similar configuration to the vehicle component 1000shown in FIGS. 1 and 2. As a departure therefrom, the wiring harness1010 has a first layer 1200 and a second layer 1205. The second layer1205 is arranged below the first layer 1200 and between the first layer1200 and the structure 1005. The cable bundle 1020 is embedded in thefirst layer 1200. In this arrangement, a first bulge 1036 adjoins thefirst layer 1200. The first layer 1200 preferably comprises a firstmaterial, and the second layer 1205 preferably comprises a secondmaterial. It is also possible for the first layer 1200 and the secondlayer 1205 to comprise an identical material. Here, the second materialcan have a different elasticity from the first material. Thus, it isadvantageous, if the elasticity of the second material is greater thanthe elasticity of the first material, that rattling of the cable bundle1020 can be avoided by means of the particularly elastic properties ofthe second layer 1205 on the structure 1005.

It is furthermore advantageous if the elasticity of the second materialof the second layer 1205 is less than the elasticity of the firstmaterial since the second layer 1205 thereby forms a kind of plate whicheffectively protects the cable bundle 1020 from possible damage.

In this embodiment, the second layer 1205 is rectangular in crosssection. Other configurations of the second layer 1205 are alsoconceivable. Thus, for example, the second layer 1205 can also be ofsemicircular, elliptical, U-shaped, C-shaped, cylindrical or some otherconfiguration.

It is also conceivable for the second layer 1205, instead of having theflat configuration shown in FIG. 3, to have a rib structure in thelongitudinal direction of the wiring harness 1010. This enables thewiring harness 1010 to be guided particularly well around a radius and,at the same time, allows a high level of protection to be provided forthe cable bundle 1020 by the second layer 1205.

FIG. 3B shows a detail of a cross section of a development of thevehicle component 1000 shown in FIG. 3A. The wiring harness 1010 is ofsubstantially identical configuration to the wiring harness 1010 shownin FIG. 3. As a departure therefrom, the second layer 1200 has a definedsurface structure 1215 on a surface 1220 facing the first layer 1200.The surface structure 1215 is of undulating configuration, for example.This increases the size of the surface 1220 of the second layer 1205 andimproves adhesion of the first layer 1205 on the second layer 1200 incomparison with the configuration shown in FIG. 3A.

FIG. 3C shows a detail of a cross section of a development of thevehicle component 1000 shown in FIG. 3A. As a departure therefrom, thefirst layer 1200 is of slimmer configuration than the second layer 1205in a direction transverse to the cable bundle 1020.

FIG. 3D shows a detail of a cross section of a development of thevehicle component 1000 shown in FIG. 3. In addition, the envelope 1030has a third layer 1210. The third layer 1210 is arranged on a side ofthe second layer 1205 facing away from the first layer 1200 and isconnected to said second layer. The third layer 1210 comprises a thirdmaterial with a third elasticity. The third elasticity is preferablyless than the first elasticity and/or the second elasticity. The thirdlayer 1210 is preferably configured as an impact plate or as an adhesivelayer. In the case of configuration as an impact plate, it isadvantageous that damage to the cable bundle 1020 can be avoided bymeans of the third layer 1210 and, at the same time, vibrations can bedamped particularly effectively by means of the second layer 1205. Inthis embodiment, by way of example, the layers 1200, 1205, 1210 arearranged in a rectangular shape of identical width in a stack of layers.The layers 1200, 1205, 1210 can also have different widths orconfigurations.

FIG. 3E shows a longitudinal section through a development of thevehicle component 1000 shown in FIG. 3A. A rib structure 1225 isprovided in the second layer 1200. The rib structure 1225 has ribs 1230and rib recesses 1235, which are arranged between the ribs 1230 in thelongitudinal direction and delimits the ribs 1230 in the longitudinaldirection. The rib recesses 1235 each have a recess base 1240, which isarranged spaced apart from the cables 1025 of the cable bundle 1020.

FIG. 4A shows a detail of a cross section through a vehicle component1000 of the motor vehicle according to a fourth embodiment. The vehiclecomponent 1000 is of substantially identical configuration to thevehicle component 1000 shown in FIGS. 1A to 3E. The structure 1005 has agroove-type recess 1300 having a recess contour 1301. By way of example,the recess 1300 is of rectangular configuration. The recess 1300 can beintroduced into the structure 1005 during a pressing operation, forexample.

The wiring harness 1010 is of substantially identical configuration tothe embodiment shown in FIG. 3A. The wiring harness 1010 is arranged inthe recess 1300. In this arrangement, the envelope 1030 has the secondbulge 1120. The second bulge 1120 is preferably formed on thecircumference, surrounding the cable bundle 1020 preferably on threesides and preferably being of layered configuration. The second bulge1120 has a bulge contour 1121. The material of the second bulge 1120 ispreferably elastic and integral and materially unitary with the materialof the envelope 1030. In the unmounted state, the bulge contour 1121 ofthe second bulge 1120 is preferably larger in this case than the recesscontour of the recess 1300.

When the wiring harness 1010 is mounted, the second bulge 1120 and thematerial thereof is compressed, with the result that the second bulge1120 presses the bulge contour 1121 thereof against the recess contourof the recess 1300, thus connecting the wiring harness 1010 frictionallyto the recess 1300 of the vehicle component 1000 via the second bulge1120. It is thereby possible to accommodate the wiring harness 1010 in aparticularly space-saving manner in the structure 1005 of the vehiclecomponent 1000.

In particular, it is advantageous here that the structure 1005 has asurface 1310 adjoining the recess 1300, wherein the upper side 1037 ofthe wiring harness 1010 is configured in such a way as to besubstantially without any transition or step relative to the surface1310. The upper side 1037 and the surface of the structure 1005preferably lie in a common plane. In the case of the wiring harness1010, it is possible here to dispense with the second bulge 1120,wherein in this configuration the wiring harness 1010 fills the recess1300 substantially completely. It is also possible for the second bulge1120 to be provided in only some section or sections in the longitudinaldirection, while the envelope 1030 is arranged at a distance from therecess contour 1305 in the remaining regions (without the second bulge1120), for example.

FIG. 4B shows a cross section through a development of the vehiclecomponent 1000 shown in FIG. 4A.

The configuration shown in FIG. 4B is substantially a combination of theconfiguration of the wiring harness 1010 shown in FIG. 3C with theconfiguration of the vehicle component 1000 shown in FIG. 4A. As adeparture therefrom, the vehicle component 1000 has, in addition to thestructure 1005, a holding structure 1006, which is arranged on the upperside at a distance from the recess 1300. Only the first layer 1200engages in the recess 1300, whereas the second layer 1205 is arrangedoutside the recess 1300, between the holding structure 1006 and thestructure 1005. The holding structure 1006 preferably presses againstthe second layer 1205 with a holding force F_(H) and thus secures thewiring harness 1010 on the structure 1005. The holding structure 1006can be secured on the structure 1005. The holding structure 1006 canalso be a different vehicle subassembly from the structure.

FIG. 5 shows a longitudinal section through a wiring harness 1010. Theenvelope 1030 of the wiring harness 1010 has a first envelope section1400, a second envelope section 1405 and a transitional section 1410.The transitional section 1410 is arranged between the first envelopesection 1400 and the second envelope section 1405 in the longitudinaldirection of the wiring harness 1010. The first envelope section 1400has a first lateral surface 1415, and the second envelope section 1405has a second lateral surface 1420. The lateral surfaces 1415, 1420 arepreferably arranged in parallel in two planes arranged offset relativeto one another at different levels. In this case, the lateral surfaces1415, 1420 are of flat configuration, by way of example. Some otherconfiguration of the lateral surfaces 1415, 1420 is also conceivable.The transitional section 1410 has a transitional surface 1425. Thelateral surfaces 1415, 1420 and the transitional surface 1425 can bearranged on the lower side of the wiring harness 1010, laterally on thewiring harness 1010 or on the upper side of the wiring harness 1010. Thetransitional surface 1425 is arranged with a slope relative to the firstlateral surface 1415 and the second lateral surface 1420. The slope hasan angle α₁, wherein the angle α₁ has a value which is less than 45°, inparticular less than 30°, in particular less than 20°, in particularless than 15°, in particular less than 10°. Cracking in the envelope1030 at the transition between the first envelope section 1400 and thesecond envelope section 1405 is thereby avoided. Of course, it is alsopossible to conceive of dispensing with the transitional section 1410.It is also conceivable for the transitional surface 1425 to be of curvedconfiguration instead of the flat configuration shown in FIG. 5. In thiscase, a convex or concave curvature is conceivable, in particular.

By virtue of the offset lateral surfaces 1415, 1420, the first envelopesection 1400 has the first transverse extent b₁ with respect to a firstdirection of longitudinal extent of the first envelope section 1400, andthe second envelope section 1405 has a second transverse extent b₂ withrespect to a second direction of longitudinal extent of the secondenvelope section 1405. Here, the first transverse extent b₁ is greaterthan the second transverse extent b₂.

By way of example, the first direction of longitudinal extent in FIG. 5is identical to the second direction of longitudinal extent. The firstdirection of longitudinal extent can also be different from the seconddirection of longitudinal extent and the transitional section 1410 canbe of curved configuration, for example. This configuration of thewiring harness 1010 has the advantage that the wiring harness 1010 canbe adapted flexibly in terms of its width to the installation spaceavailable on the structure 1005.

FIG. 6 shows a perspective view of a wiring harness 1010 in anotherembodiment.

The wiring harness 1010 is of similar configuration to the wiringharness 1010 shown in FIGS. 1 to 5. As a departure therefrom, thelateral surface 1035 is configured with an illustrative undulatingprofile 1500. The profile 1500 has a first profile section 1505 and asecond profile section 1510. By way of example, the first profilesection 1505 is of wider configuration in the longitudinal directionthan the second profile section 1510. Preferably, the first profilesection 1505 is of concave configuration and the second profile sectionis of convex configuration. The first and second profile sections 1505,1510 alternate in the longitudinal direction.

FIG. 7 shows a perspective view of a wiring harness 1010 in anotherembodiment.

The wiring harness 1010 is of substantially identical configuration tothe wiring harness 1010 shown in FIG. 6. As a departure therefrom, thefirst profile section 1505 and the second profile section 1510 areconfigured with an identical width.

FIG. 8 shows a perspective view of a wiring harness 1010 in anotherembodiment.

The wiring harness 1010 is of substantially identical configuration tothe wiring harness 1010 shown in FIG. 6. As a departure therefrom, theprofile 1500 is of substantially rectangular configuration, wherein thefirst profile section of the wiring harness 1010 shown in FIG. 6 is ofsubstantially flat configuration and the second profile section 1510 isconfigured as a recess in the lateral surface 1035.

FIG. 9A shows a perspective view of a mold system 10 for manufacturingat least one wiring harness 1010 shown in FIGS. 1 to 8.

The mold system 10 preferably has a mold 15 and a mounting board 20. Byway of example, the mounting board 20 is flat. The mold 15 can have afirst mold part 16 and at least one second mold part 17, which each abutat one longitudinal end 18 and are arranged by means of a lower side 19on an upper side 25 of the mounting board 20, preferably in a commonplane.

FIG. 9B shows a detail of a plan view of the mold system 10 shown inFIG. 9A.

On the upper side 25, by way of example, the mounting board 20 has agrid 27 comprising a plurality of first sockets 142 of identicalconfiguration to one another. The first sockets 142 are arranged in aregular pattern in the grid 27. For reasons of clarity, only some of thefirst sockets 142 have been illustrated in FIG. 9B.

FIG. 10 shows a perspective view of the first mold part 16 of the mold15 according to a first embodiment, which is shown in FIG. 9A and FIG.9B.

To make it easier to explain the mold 15, reference is made below to acoordinate system 26. The coordinate system 26 is preferably configuredas a right-hand system and has an x direction (direction of transverseextent), a y direction (longitudinal direction) and a z direction(height).

The mold 15 has a wall 30, an opening 35 and a holding device 40. Thewall 30 delimits a mold cavity 45. During the manufacture of the wiringharness 1010, the cable bundle 1020 and the envelope 1030 are introducedinto the mold cavity 45 via the opening 35. The opening 35 is arrangedon the upper side and adjoins the mold cavity 45. In this embodiment, byway of example, the mold cavity 45 is configured with a rectangularcross section. It is also possible for the mold cavity 45 to beconfigured in some other way and to have a different cross section.Thus, for example, it is also conceivable for the mold cavity 45 to beof polygonal, triangular, rounded, circular and/or ellipticalconfiguration (in some section or sections).

The wall 30 has a first wall section 50, a second wall section 55 and awall bottom 60. The wall bottom 60 is arranged between the first wallsection 50 and the second wall section 55. The first wall section 50 andthe second wall section 55 delimit the mold cavity 45 laterally. Thewall bottom 60 delimits the mold cavity 45 at the bottom. The opening 35is preferably arranged above the wall bottom 60.

The first wall section 50 has a first wall surface 61 facing the moldcavity 45, the second wall section 55 has a second wall surface 62facing the mold cavity 45, and the wall bottom 60 has a wall base 63facing the mold cavity 45. In this embodiment, by way of example, thefirst and second wall surfaces 61, 62 extend in parallel. The wall base63 is arranged perpendicularly to the first wall surface 61 and to thesecond wall surface 62. The wall base 63 and/or the wall surface 61, 62can also be arranged in a different way. Thus, the first wall surface 61can be arranged obliquely to the second wall surface 62. It would alsobe conceivable for the first wall surface 61 and the second wall surface62 to adjoin one another directly and to dispense with the wall bottom60, with the result that the mold cavity 45 has a triangular crosssection, for example.

It is particularly advantageous here if at least one of the wallsurfaces 61, 62 and/or the wall base 63 is laser-polished, at least insome section or sections. A particularly good surface finish can therebybe ensured. Furthermore, scoring and/or grooves, caused, for example, byintroducing the mold cavity 45 into a basic body to produce the mold 15by means of a machining process, is/are at least partially eliminated bythe laser polishing. A mold 15 which is stable over a particularly longtime, by means of which a large number of wiring harnesses 1010 can beproduced without additional preparation of the mold 15, is therebyensured.

In contrast to the flat configuration of the wall surface 61, 62 and/orof the wall base 63, it is also possible for the wall surface 61, 62and/or the wall base 63 to be profiled in an undulating and/orrib-shaped manner, at least in some section or sections.

The holding device 40 comprises a first holding element 65, a secondholding element 70, a first contact pressure element 75, a secondcontact pressure element 80 and a first fastening means 85. By way ofexample, the first holding element 65 and the second holding element 70are configured symmetrically with respect to a plane of symmetry 86,which preferably passes centrally through the mold cavity 45. The planeof symmetry 86 is preferably configured as a YZ plane. It is alsopossible for the first holding element 65 and the second holding element70 to be configured differently from one another.

The mold 15 is connected positively to the mounting board 20 by means ofa second fastening means 135, which, in this embodiment, by way ofexample, has at least one pin 140 configured as a first engagementelement, by way of example. Here, the pin 140 is connected to the wall30 and engages by means of a free longitudinal end 141 in the firstsocket 142 of the grid 27 of the mounting board 20, said socket beingconfigured to correspond to the pin 140. In order to provideparticularly simple mounting of the mold 15 on the mounting board 20,there is for this purpose preferably a plurality of pins 140 configuredcorrespondingly to the first sockets 142 and identically to one another,said pins being connected to the wall 30. Depending on the alignment ofthe mold 15, the pins 140 each engage in a first socket 142 of the grid27, whereas the other first sockets 142 of the grid 27 remain free. Inthis case, the engagement can additionally be secured nonpositively inorder to prevent the mold 15 accidentally dropping off the mountingboard 20, e.g. when the mold system 10 is supposed to be tilted. It ispossible to achieve this, for example, by configuring the pin 140 andthe socket 142 as a transition fit system or as an interference fitsystem.

The second fastening means 135 can also be configured in a differentway. In particular, it is possible here to conceive of the secondfastening means 135 being designed as a screw system.

The first socket can also be arranged on the lower side 19 of the moldpart 16, 17. On the upper side of the mounting board 20, the mountingboard 20 preferably has a multiplicity of pins 140 configured as firstengagement elements.

Instead of the first sockets 142, the grid 27 can alternatively have thepins 140 configured as first engagement elements extending in thedirection of the mold 15. In this alternative, the first socket 142 isarranged on the mold 15, preferably in the wall 30. Depending on thealignment of the mold 15, some of the pins 140 of the grid 27 eachengage in the first sockets 142 in the mounted state of the mold 15 onthe mounting board 20 and, as described above, secure the mold 15reversibly on the mounting board 20. The other pins 140, which do notengage in the first socket 142, remain (at least circumferentially) freeand/or covered at least in some section or sections (on the upper side)by the mold 15. FIG. 11A shows a section through the mold 15 shown inFIG. 10, along a section plane A-A shown in FIG. 10, in a closedposition of the holding elements 65, 70.

The first holding element 65 is of plate-type configuration andcomprises a first section 90 and a second section 95. In this case, afirst section 90 of the first holding element 65 is arranged on theupper side of the first wall section 50. The first contact pressureelement 75 is arranged on the upper side of the first section 90. Thefirst contact pressure element 75 is preferably connected nonpositivelyto the first wall section 50 by means of the first fastening means 85.In this case, the first fastening means 85 supplies a first clampingforce F_(s1), with which the first contact pressure element 75 pressesthe first holding element 65 onto the upper side of the first wallsection 50. In this embodiment, the first contact pressure element 75is, by way of example, configured to be precisely the same width in theX direction as the first wall section 50. It is thereby possible toensure that the first holding element 65 is pressed reliably intocontact by the first contact pressure element 75. Unwanted deformationof the first holding element 65 can furthermore be avoided.

A first free end 100 of the first holding element 70 ends above theopening 35. A second section 95 of the first holding element 65, whichadjoins the first free end 100 of the first holding element 65, coversthe opening 35 at the top. The second section 95 can preferably be ofwedge-shaped configuration, at least in some section or sections. It isparticularly advantageous here if a first lower side 105 of the firstholding element 65 is of substantially flat configuration and if thefirst holding element 65 becomes thicker on the upper side (Z direction)from the free end 100 toward the first wall section 50.

The second holding element 70 is preferably at the same height on theopposite side, that is to say, by way of example, is arranged in acommon XY plane, with respect to the first holding element 65. Thesecond holding element 70 is arranged in mirror symmetry with respect tothe plane of symmetry 86. The second holding element 70 is arranged onthe upper side of the second wall section 55 and has a third section 110and a fourth section 115, as well as being of plateshaped configurationby way of example. The third section 110 of the second holding element70 rests on the upper side of the second wall section 55. The secondcontact pressure element 80 is arranged above the third section 110. Thefirst fastening means 85 supplies a second contact pressure force F_(s2)for the second contact pressure element 80, with which the secondcontact pressure element 80 presses the second section 110 onto theupper side of the second wall section 55. Here, by way of example, thesecond contact pressure element 80 is configured to be of exactly thesame width as the second wall section 55. In this case, the firstcontact pressure element 75 and the second contact pressure element 80laterally delimit a first gap 120, which is exactly the same width asthe opening 35.

The fourth section 115 adjoins a second free end 130 of the secondholding element 70. Like the second section 95, the fourth section 115is of wedge-shaped configuration, wherein a second lower side 125 of thesecond holding element 70 is arranged in a common plane with the firstlower side 105 of the first holding element 65. The second free end 130ends above the opening 35. On the upper side, the fourth section 115thickens from the second free end 130 toward the third section 110.

Here, the fourth section 115 adjoins a second free end 130 of the secondholding element 70.

The first free end 100 is preferably arranged at a distance from thesecond free end 130 of the second holding element 70. Here, a distance abetween the first free end 100 and the second free end 130 is preferably10 times smaller than a width of the opening 35 (in relation to a commonXZ plane).

As a result, the holding device (40) covers only a section of theopening 35. The first free end 100 and the second free end 130 can alsobe in direct contact with one another.

It is particularly advantageous if the holding element 65, 70 comprisesa material which is particularly elastic and can be bent reversibly, atleast by 90°, preferably into the mold cavity 45. It is particularlyadvantageous here if the holding element 65, 70 comprises silicone asthe material. This furthermore enables the holding device 65, 70 to beconfigured to follow the geometrical configuration of the wall section50, 55.

FIG. 11B shows a section through a variant of the mold 15 shown in FIG.10, along the section plane A-A shown in FIG. 10.

The mold 15 is of substantially identical configuration to theconfiguration shown in FIG. 11A. As a departure therefrom, the firstholding element 65 and the second holding element 70 are of brush-typeconfiguration. In this case, the first holding element 65 has a firstbrush 66 with a multiplicity of brush fibers 67, and the second holdingelement 70 has a second brush 71 with a multiplicity of second brushfibers 72.

The brush fibers 67, 72 extend substantially in the transversedirection. In this case, the second section 95 and the fourth section115 are wider than half the width of the opening 35 in the transversedirection (x direction). As a result, the brushes 66, 71 extend into therespectively opposite brush 66, 71 and completely close the opening 35at the top. It is also possible for the free ends 100, 130 to bearranged at a distance from one another, as shown in FIG. 11A.

FIG. 12 shows a section through a first mold part 16 according to asecond embodiment along the section plane A-A shown in FIG. 10.

The mold 15 is of similar configuration to the mold 15 shown in FIGS. 9Ato 11. As a departure therefrom, the second section 95 and the fourthsection 115 of the holding elements 65, 70 are arranged so as to partlyoverlap above the opening 35. Here, an overlap is taken to mean thatthey at least partly overlap when the second section 95 and the fourthsection 115 are projected into a common XY plane.

The wall 30 of the first mold part 16 is of integral and materiallyunitary configuration. Here, the wall 30 advantageously comprises atleast one of the following materials: polypropylene (PP),polytetrafluoride (PTFE), polyethylene (PE), preferably polyethylenewith highly branched polymer chains (PE-LD), polyoxymethylene (POM). Inaddition or as an alternative, it is also conceivable for the wall 30 tocomprise a material which has a particularly low surface tension withrespect to polyurethane and/or silicone.

FIG. 13 shows a perspective view of a first mold part 16 according to athird embodiment.

The first mold part 16 is of similar configuration to the mold 15 shownin FIGS. 10 to 12. As a departure therefrom, the first mold part 16 hasan increased longitudinal extent as compared with the configurationshown in FIG. 10.

The holding device 40 is configured to correspond to the increasedlongitudinal extent. In order to enable the second fastening means 135to be mounted on the upper side of the wall 30, a first recess 145 isadditionally provided here in the holding device 40, preferably on aside facing away from the opening 45. In this case, by way of example,the first recess 145 in the holding device 40 extends both across theholding element 65, 70 and across the contact pressure element 75, 80.The first recess 145 leads to a slimmer configuration in the Xdirection, i.e. transversely to the longitudinal extent of the mold 15and of the holding device 40 in the region of the second fastening means135.

Moreover, the first fastening means 85 and the second fastening means135 can be combined with one another, and therefore the mold 15 and theholding device 40 are secured on the mounting board 20 by means of thecombined fastening means 85, 135.

In addition, a sealing element 150 (illustrated in dashed lines) isprovided opposite the mold 15 shown in FIGS. 9A to 12, at thelongitudinal end 18 of the mold 15. The sealing element 150 delimits themold cavity 45 at the longitudinal end 18. In this case, the sealingelement 150 can be of plate-type configuration. It is particularlyadvantageous here if the sealing element 150 is arranged exclusively atthe longitudinal end 18 at which the mold part 16 does not adjoin anyother mold part 17. This makes it possible to avoid emergence of theenvelope 1030 at the longitudinal end 18 of the mold 15 during themanufacture of the wiring harness 1010.

FIG. 14 shows a detail of a perspective view of the mold 15.

The first mold part 16 can be configured as described in FIGS. 9A to 13.The mold 15 additionally has a cover 155 on top of the wall 30. Thecover 155 is connected to the wall 30 of the first mold part 16 by meansof a third fastening means 160. Here, the cover 155 is arranged on theupper side of the holding device 40 (not illustrated in FIG. 14) andprevents the holding elements 65, 70 from being bent up in a directionaway from the mold cavity 45.

FIG. 15 shows a perspective view of a development of the mold 15 shownin FIGS. 9A to 14.

The mold 15 is of similar configuration to the mold 15 shown in FIGS. 9Ato 14. As a departure therefrom, different variants of the holdingdevice 40 are shown in FIG. 15.

The holding device 40 comprises a multiplicity of holding elements 65,70 arranged at regular intervals in the longitudinal direction (xdirection). The holding elements 65, 70 are each connected to the wallsection 50, 55. The holding element 65, 70 preferably extendsperpendicularly to an upper side 165 of the wall 30. In these variantsof the holding elements 65, 70, each of the holding elements 65, 70 hasa different cross section in a plane parallel to the upper side 165 (xyplane). Thus, for example, the holding element 65, 70 can have acircular cross section, a rectangular cross section, a trapezoidal crosssection, an elliptical cross section and/or a circular cross section. Itis also conceivable that the holding element 65, 70 tapers away from theupper side 165 of the wall 30. In this case, it is particularlyadvantageous if the holding element 65, 70 has a wedge-shaped crosssection away from the upper side 165 of the wall 30, wherein a free end170 of the holding element 65, 70 is set back from the wiring harness1010. It is thereby possible to facilitate insertion of individualcables 1020 of the cable bundle 1015.

In this embodiment, the first holding element 65 is in each casearranged opposite the second holding element 70, with the result thatthe first and the second holding element 65, 70 are each arranged in acommon XZ plane.

Of course, the first and the second holding element 65, 70 can also eachbe arranged offset relative to one another.

FIG. 16 shows a perspective view of a development of the mold 15 shownin FIGS. 9A to 15. For reasons of clarity, the holding device 40 is notillustrated in FIG. 16.

The mold 15 is of similar configuration to the mold 15 shown in FIGS. 9Ato 15. As a departure therefrom, the wall 30 on the first wall section50 has a first web 175 at the side, and the second wall section 55 has asecond web 180 at the side. The web 175, 180 extends away from the moldcavity 45 and adjoins the lower side 19 of the first mold part 16.Furthermore, a plurality of first apertures 185 is preferably providedin each web 175, 180. In this case, the first aperture 185 is preferablyconfigured as a slotted hole. This enables the first mold part 16 to bepositioned in a particularly accurate way in the longitudinal direction,and therefore the first mold part 16 rests by means of its longitudinalend 18 and the end face 190 adjoining the latter on a further end face195 of the further mold part 17 arranged at the longitudinal end 18.

For the first aperture 185, the second fastening means 135 preferablyhas a screw instead of the pin 140. It is also possible, as shown inFIG. 10, for the mold part 16, 17 to be connected to the mounting board20 by means of pins 140, which are anchored in the web 180, 175, forexample.

The cable bundle 1020 of the wiring harness 11 is inserted into the moldcavity 45. In this case, by way of example, the cable bundle 12 is heldin a predefined position by means of a first fastening element 200, 205.The first fastening element 200 is supported on the wall 30 on a sidefacing away from the cable bundle 12 and is embedded in the envelope1030 of the wiring harness 1010.

More details of the first fastening element 200 are given in FIGS. 27 to30.

FIG. 17 shows a detail of a perspective view of a development of themold 15 shown in FIG. 16.

The mold 15 is of similar configuration to the mold 15 shown in FIG. 16.As a departure therefrom, the first mold part 16 has a second engagementelement 205 and the second mold part 17 comprises a second socket 210configured to correspond to the second engagement element 205 in orderto ensure reliable connection of the first mold part 16 to the secondmold part 17. In this case, the second engagement element 205 isarranged against the end face on the longitudinal end 18 of the firstmold part 16. The second engagement element 205 engages in the secondsocket 210, thus ensuring that the first mold part 16 is coupledpositively to the second mold part 17. It is thereby possible to definea reliable alignment of the mold parts 16, 17 relative to one another.In particular, this ensures that, as shown in FIG. 17, the mold cavity45 extends in a straight line via a transition between the first moldpart 16 and the second mold part 17 and a leak at the transition isavoided.

FIG. 18 shows a perspective view of the first mold part 16 according toa fourth embodiment.

Here, the first engagement element 205 is arranged on the end face ofthe webs 175, 180. In this case, by way of example, two secondengagement elements 205, which are each preferably arranged on the web175, 180, are provided for the end face 190 of the first mold part 160.Here, the first engagement element 205 has a trapezoidal cross sectionwhen sectioned in an xy plane, wherein the second engagement element 205thickens away from the end face 190 of the first mold part 16. FIG. 19shows a perspective view of the mold 15 comprising the first mold part16 shown in FIG. 18 and a second mold part 17 configured to correspondto the first mold part 16. The second mold part 17 has the second socket210, which is configured to correspond to the second engagement element205 of trapezoidal configuration in FIG. 18. The second engagementelement 205 engages in the second socket 210. By virtue of thetrapezoidal cross section of the second engagement element 205, the twomold parts 16, 17 can be detached from one another only in the Zdirection. It is thereby possible to ensure that no gap forms betweenthe two end faces 190, 195 and thus that the mold cavity 45 is sealed atthe end face.

Furthermore, the configuration of the second socket 210 and of thesecond engagement element 205 ensures that the mold parts 16, 17 can bedetached reversibly from one another. In this way, the mold system 10can be adapted particularly quickly to different configurations for themanufacture of the wiring harness 1010. Setup times for the mold system10 can thereby be reduced.

FIG. 20 shows a perspective illustration of the wall 30 in a developmentof the mold 15 shown in FIGS. 10 to 19.

In this case, by way of example, the wall 30 is configured with a lowwall thickness. The wall 30 can be deep-drawn, for example.

The first wall section 50 has a first wall region 215 and a second wallregion 220. By way of example, the first wall region 215 and the secondwall region 220 adjoin one another in the longitudinal direction. Thesecond wall section 55 is preferably configured symmetrically withrespect to the plane of symmetry 86 to the first wall section 50 and hasa third wall region 225 and a fourth wall region 230. The fourth wallregion 230 is preferably arranged opposite the second wall region 220 inthe transverse direction (x direction), and the third wall region 215 ispreferably arranged opposite the first wall region 215 in the transversedirection. The first wall region 215 and the third wall region 225preferably extend in parallel. The second and the fourth wall region220, 230 are of arc-shaped configuration, by way of example.

The second wall region 220 is arranged set back relative to the secondwall section 55. For example, the fourth wall region 230 is arranged setback relative to the second wall region 220, such that the mold cavity45 has a widened portion 235 between the second wall region 220 and thefourth wall region 230. The widened portion 235 can be used to form thesecond bulge 1120. It is also conceivable for at least one of the wallregions 220, 225, 230, 235 to have a different geometricalconfiguration.

FIG. 21 shows a perspective illustration of the wall 30 in a variant ofthe configuration shown in FIG. 20. As a departure therefrom, the secondand the fourth wall region 220, 230 are of longer configuration in thelongitudinal direction (y direction) than in FIG. 20. In this case, thesecond wall region 220 and the fourth wall region 230 form a widenedportion 235 in the form of a slotted hole.

Furthermore, the wall 30 has a second aperture 240 in the wall bottom 60at the level of the second and the fourth wall region 220, 230 in thelongitudinal direction. By way of example, the second aperture 240 is ofrectangular configuration and is configured as a through opening in thewall bottom 60. In this case, the second aperture 240 is configured toaccommodate a second fastening element 400 (not shown). Further detailsof the second fastening element 400 are given in FIGS. 31 and 32. Thesecond aperture 240 can also be arranged in the wall section 50, 55.

It is also possible for the second aperture 240 to be configured tocorrespond to an ejector 245 (illustrated in dashed lines in FIG. 21) inorder to push the wiring harness 1010 out of the mold 15 from belowafter the manufacture of the wiring harness 1010 in the mold 15. It isthereby possible to avoid damage to the wiring harness 1010, inparticular to the envelope 1040, since the envelope 1040 is subjectedonly to a compression load and not to a tensile load substantially bythe ejector 245. The ejector 245 can rest directly on the envelope 1040or can be applied to the second fastening element 400. If no secondfastening element 400 is inserted into the second aperture 240 duringthe manufacture of the wiring harness 1010, the mold cavity 40 is opentoward the bottom via the second aperture.

FIG. 22 shows a perspective view of the mold 15 in another embodiment.The wall 30 is of similar configuration to the wall 30 shown in FIGS. 20and 21. As a departure therefrom, the wall 30 delimits a plurality ofmold cavities 45, which open into one another in a common region 241.Here, the geometrical configuration shown in FIG. 22 is illustrative.The wall 30 can also be configured in some other way. The opening of themold cavities 45 into the common region enables individual cable bundles1020 and/or cables 1025 of the wiring harness 1010 to be branched orcombined in a simple manner in the mold 15.

FIG. 23 shows a longitudinal section through the mold 15 in anotherembodiment. The mold 15 is of similar configuration to the mold 15 shownin FIGS. 9A to 22. The wall base 63 and/or the wall section 55, 60 has afirst wall surface section 250, a second wall surface section 255 and awall surface transitional section 260. The wall surface transitionalsection 260 is arranged between the first wall surface section 250 andthe second wall surface section 255 in the longitudinal direction. Inthis case, the first wall surface section 250 is arranged lower than thesecond wall surface section 255. In this case, the first wall surfacesection 250 and the second wall surface section 255 are each arranged soas to extend in planes arranged offset relative to one another,preferably in parallel. The wall surface transitional section 260 isarranged with a slope relative to the first wall surface section 250 andto the second wall surface section 255. It is advantageous if the slopeof the wall surface transitional section 260 has an angle α2, whereinthe angle α2 has a value which is less than 45°, in particular less than30°, in particular less than 20°, in particular less than 15°, inparticular less than 10°. The wall surface section 250, 255 and the wallsurface transitional section 260 enable the envelope section 1400, 1405and the transitional section 1410 of the wiring harness 1010 to beformed.

FIG. 24 shows a perspective view of a mold 15 in another embodiment.

The mold 15 is of similar configuration to the mold 15 shown in FIGS. 9Ato 23. As a departure therefrom, the wall surface 61, 62 is configuredin an undulating manner to correspond to the shaping of the profile 1500of the wiring harness 1010 shown in FIG. 6.

FIG. 25 shows a perspective view of a mold 15 in another embodiment. Themold 15 is of similar configuration to the mold 15 shown in FIG. 24,wherein the wall surface 61, 62 is configured in an undulating manner tocorrespond to the shaping of the profile 1500 of the wiring harness 1010shown in FIG. 7.

FIG. 26 shows a perspective view of a mold in another embodiment.

The mold 15 is of similar configuration to the mold 15 shown in FIG. 24and FIG. 25, wherein the wall surface 61, 62 is configured in arib-shaped manner to correspond to the shaping of the profile 1500 ofthe wiring harness 1010 shown in FIG. 8.

FIG. 27 shows a perspective view of the first fastening element 200according to a first embodiment.

The first fastening element 200 has a fastening plate 300, a firstfastening bracket 305 and a second fastening bracket 310. The firstfastening bracket 305 and the second fastening bracket 310 are arrangedspaced apart relative to one another in the longitudinal direction onthe fastening plate 300. In this embodiment, the fastening plate 300 isof flat configuration by way of example. It is also possible for thefastening plate 300 to be of curved shape. The fastening plate 300 restsby means of a lateral surface 315 facing away from the fastening bracket305, 310 on the wall surface 61, 62 and/or on the wall base 63. Thefastening bracket 305, 310 has at least one laterally arranged bearingsurface 311, 312, which preferably rests respectively on the wallsurface 61, 62 associated therewith.

The first fastening bracket 305 has a third aperture 320. The secondfastening bracket 320 has a fourth aperture 325. The third and/or thefourth aperture 320, 325 are/is configured to correspond to the cablebundle 1020 or to one or more cables 1025 of the cable bundle 1020. Thethird and/or fourth aperture 320, 325 can preferably be of circularconfiguration. Other cross sections are also conceivable. In this case,the third and the fourth aperture 320, 325 are arranged opposite oneanother in the longitudinal direction.

The first fastening bracket 305 has a first insertion opening 330, andthe second fastening bracket 310 has a second insertion opening 335. Thefirst insertion opening 330 opens into the third aperture 320. Thesecond insertion opening 335 opens into the fourth aperture 325. In thiscase, the insertion openings 330, 335 are arranged on opposite sides ofthe respective fastening bracket 305, 310 in the transverse direction (Xdirection). Here, the insertion opening 330, 335 can preferably enclosea 90° angle segment. Stable fixing and positioning of the cable bundle1020 and/or of one or more cables 1025 of the cable bundle 1020 in themold cavity 45 by means of the first fastening element 200 is therebyensured.

FIG. 28 shows a perspective view of a first fastening element 200according to a second embodiment.

The first fastening element 200 is of similar configuration to theembodiment of the first fastening element 200 shown in FIG. 27. As adeparture therefrom, the fastening bracket 305, 310 is preferably ofhook-type configuration. The first fastening bracket 305 has a firstbracket section 340 and a second bracket section 345. In this case, byway of example, the first bracket section 340 is formed perpendicularlyto the fastening plate 300. The second bracket section 345 is orientedperpendicularly to the first bracket section 340 and, by way of example,parallel to the fastening plate 300. The second fastening bracket 310 ispreferably of identical configuration to the first fastening bracket305. As a departure therefrom, the second fastening bracket 310 isarranged offset with respect to the first fastening bracket 305 in thelongitudinal direction (y direction). In this case, the second bracketsection 345 of the second fastening bracket 310 extends in the directionof the second bracket section 345 of the first fastening bracket 305 (xdirection) and is preferably arranged parallel to the first fasteningbracket 305.

It is also possible, as shown in FIG. 28, adjoining a free end 349 ofthe second bracket section 345, for the second bracket section 345 to beof wedge-shaped configuration on a side facing the fastening plate 300.

FIG. 29 shows a perspective illustration of a first fastening element200 according to a third embodiment.

The first fastening element 200 is of similar configuration to the firstfastening element 200 shown in FIG. 28. As a departure therefrom, thesecond bracket section 345 of the first and/or of the second bracketsection 305, 310 is arranged with a slope relative to the fasteningplate 300. In this case, the second bracket section 345 extendsobliquely downward toward the fastening plate 300. As a result, an anglebetween the first bracket section 340 and the second bracket section 345is smaller than 90°. A supporting section 350 is furthermore providedbetween the first bracket section 340 and the fastening plate 300. Inthis case, the supporting section 350 has, on a side facing the secondbracket section 345, a supporting surface 355, preferably configured tocorrespond to the cable bundle 1020 and/or to one or more cables 1025 ofthe cable bundle, being rounded for example. The cable bundle 1020 canthereby be fixed particularly well in the mold cavity 45 by thefastening brackets 305, 310.

FIG. 30 shows a perspective view of a first fastening element 200according to a fourth embodiment.

The first fastening element 200 is of similar configuration to the firstfastening element 200 shown in FIG. 28. As a departure therefrom, thefirst fastening bracket 305 and the second fastening bracket 310 arearranged at the same level in the longitudinal direction (y direction).Furthermore, the second bracket section 345 of the first fasteningbracket 305 tapers toward the second bracket section 345 of the secondfastening bracket 310. Here, the taper is preferably configured in sucha way that the second bracket section 345 is of wedge-shaped design. Thesecond bracket section 345 of the second fastening section 310 is ofsimilar configuration to the second bracket section 345 of the firstfastening bracket 305 and tapers toward the second bracket section 345of the second fastening bracket 310. A second gap 360 is arrangedbetween the second bracket section 345 of the first fastening bracket305 and the second bracket section 345 of the second fastening bracket310. Via the second gap 360, the cable bundle 1020 or individual cables1025 of the cable bundle 1020 can be inserted, with the result that thecables 1025 of the cable bundle 1020 are surrounded by the fasteningbrackets 305, 310. This enables the cable bundle 12 to be positioned ina predefined position in the mold cavity 45.

FIG. 31 shows a perspective illustration of a second fastening element400.

The second fastening element 400 comprises a supporting plate 405, afirst engagement section 410 and a second engagement section 415. By wayof example, the first engagement section 410 is arranged on the upperside of the supporting plate 405 in FIG. 31. The second engagementsection 415 is arranged on the lower side of the supporting plate 405.The supporting plate 405 is configured to taper outward toward theboundary edge 420 thereof. The first engagement section 410 is offirtree-type configuration and has at least one engagement plate 425,which extends obliquely to the fastening plate 405 and is preferablyarranged on all sides of the first engagement section 410. In this case,the engagement plates 425 are embedded in the envelope 1030 of thewiring harness 1010. The firtree-type configuration makes it possible toachieve partitularly good fixing of the wiring harness 1010 on thesecond fastening element 400 via the envelope 1030.

The second engagement section 415 preferably has a rib-shaped structure430 on the outside. In this case, the second engagement section 415 isconfigured to engage in an opening 435 in the structure 1005 of thevehicle component 1000 of the motor vehicle. This enables the wiringharness 11 to be fixed particularly well on the structure 1005.

It is particularly advantageous here if the second aperture 240 (cf.FIG. 21) is configured to correspond to the second engagement section415 and the supporting plate 405 is of larger configuration on the upperside than the second aperture 240. As a result, the fastening plate 405simultaneously acts as a sealing element and delimits the mold cavity 45at the bottom, for example. Furthermore, a step in the envelope 1030 ofthe wiring harness 1010 is reduced by the fact that the supporting plate405 tapers toward the outside.

FIG. 32 shows a perspective view of the second fastening element 400according to a second embodiment. Here, the secand fastening element 400is a combination of the first fastening element 200 shown in FIG. 29 andthe second fastening element 400 shown in FIG. 31. In this case, thefastening plate 300 of the first fastening element 200 is of integraland materially unitary configuration with the supporting plate 405 ofthe second fastening element 400. By way of example, the firstengagement section 410 is dispensed with. Furthermore, by way ofexample, two first fastening elements 200 are arranged on the fasteningplate 405. A position of the cable bundle 1020 and/or of at least onecable 1025 in the mold cavity 45 can be ensured by means of the firstfastening element 200. At the same time, the wiring harness 1010 can befixed reliably on the structure 1005 by means of the second engagementsection 415 after the manufacture of the wiring harness 1010. At thesame time, the supporting plate 405 preferably enters into a materialjoint with the envelope 1030 of the wiring harness 1010.

FIG. 33 shows a flow diagram of a method for manufacturing the wiringharness 1010. FIG. 34 shows a plan view of the mold system 10 during athird method step and FIG. 35 shows a section along a section plane D-Dshown in FIG. 34.

The mold system 10 is supplied in a first method step 3000. Here,heating of the mold 15 is dispensed with, and therefore the mold 15 issubstantially at room temperature. Also dispensed with is theintroduction of a mold release agent into the mold cavity 45, inparticular on to the wall surface 61, 62 and/or the wall base 63. It isthereby possible to avoid a situation where the cables 1025 come intocontact with the mold release agent and an envelope 1030 to beintroduced cannot adhere to the cables 1025.

In a second method step 3005, which is optional, the first fasteningelement 200 and/or the second fastening element 400 are introduced intothe mold cavity 45. During this process, the second engagement element415 is inserted into the second aperture 240 until the supporting plate405 is resting on the wall base 63 or on the wall surface 61, 62. Thefirst fastening element 200 is inserted in such a way that it does notproject from the mold 15 at the top and/or rests by means of the bearingsurface 311, 312 on the wall surface 61, 62 or is preferably seated onthe wall base 63 on the lower side.

In a third method step 3010, the individual cables 1025 of the cablebundle 1020 are inserted. During this process, the first holding element65 and the second holding element 70 are deformed reversibly out of aclosed position in a first region 1605 by means of a means 1600 in sucha way that an insertion opening 1610 is formed between the holdingelements 65, 70. For example, the first and the second holding element65, 70 are bent into the mold cavity 40 or bent away from the moldcavity 40. By way of example, the insertion opening is delimited in thelongitudinal direction by the means 1600 and in the transverse directionby the first and the second holding element 65, 70. The means 1600 canbe a mechanical tool and/or finger of a human hand and/or the cable 1025to be inserted. By way of example, a section of the means 1600 projectsinto the mold cavity 40 at the top.

In a second region 1615, which adjoins the first region 1605 on bothsides in the longitudinal direction, the holding elements 65, 70 are inthe closed position. In addition, the first and/or the second fasteningelement 200, 400 optionally ensure/s a defined position of a predefinedcable 1025 of the cable bundle 1020 relative to the further cables 1025of the cable bundle 1020. The first and/or the second fastening element200, 400 can also position and secure the cable bundle 1020 in itsposition in the mold cavity. In particular, heating of the cable bundle1020 in the wiring harness 1010 can be precisely defined by virtue ofthe defined arrangement of one or more cables 1025 in the cable bundle1020. In particular, overheating of the wiring harness 1010 is avoidedin this case. As a result, possible self-ignition of the wiring harness1010, short circuits or other irreversible damage to the wiring harness1010 are avoided.

In addition, the holding device 40 prevents the cables 1025 from slidingout of the mold cavity 45 in the second region 1615. Via the insertionopening 1610, at least one of the cables 1025 of the cable bundle 1020is inserted by moving the means 1600 in the longitudinal directionfollowing the mold cavity 40 and, in parallel therewith, inserting thecable 1025 to be inserted from above into the mold cavity 40 via theinsertion opening 1610. During the movement of the means 1600, theholding elements 65, 70 bend open in front of the means 1600 and formthe insertion opening 1610 and, after the means 1600 has passed, theymove back into their closed position and cover the opening 35 of themold cavity 40.

By means of the geometrical configuration of the holding device 40 whichis described in FIGS. 10 to 15, the cables 1025 can be insertedparticularly quickly manually but also automatically, thus enabling thewiring harness 1010 to be manufactured at particularly low cost.Furthermore, the insertion of the cable 1025 into the mold 15 with theholding device 40 is perceived to be particularly ergonomic.

In a fourth the method step 3015, the material of the envelope 1030 isintroduced into the mold cavity 45 at the top via the opening 35 in alow-pressure process. For this purpose, the holding elements 65, 70 canonce more be bent reversibly out of their closed position (e.g. into themold cavity 40 or away from the mold cavity 40) in order to introducethe material of the envelope 1030 into the mold cavity.

During this process, the second material for the formation of the secondlayer 1205 (cf. FIG. 3) is preferably introduced first, after which thefirst material of the first layer 1200 is introduced. Both the first andthe second material are preferably free-flowing while being introduced.During the processing time of the material, the material sinks in thedirection of gravity and, in the process, surrounds the cables 1025 ofthe cable bundle 1020. The second material builds up at the wall base 63and the second layer 1205 is formed. It is particularly advantageoushere if the first material is applied to the second material when thesecond material is already curing and the processing time of the secondmaterial has preferably already expired.

If at least part of the mold 15 is configured as described in FIG. 5, itis particularly advantageous if the material is introduced first abovethe first wall surface section 250 and, after the lower-lying first wallsurface section 250 has been filled up, is introduced into the secondwall surface section 255 above the second wall surface section 255.Finally, the material is introduced above the wall surface transitionalsection 260. This procedure has the advantage that the material isprevented from running down toward the first wall surface section 250from the second wall surface section 255 via the wall surfacetransitional section 260.

During the introduction of the material into the mold cavity 45, it isparticularly advantageous if the material of the envelope 1030 isapplied in a manner fluctuating in an undulating fashion in a planeparallel to the wall base 63 between the first wall section 50 and thesecond wall section 55. Reliable embedding of the cables 1025 of thecable bundle 1020 in the envelope 1030 is thereby ensured.

If the material is configured in such a way that it foams during curing,the holding device 40 additionally prevents the cable bundle 1020 frombeing pushed out of the mold cavity 45 at the top and secures the cablebundle 1020 in the mold cavity 45. Secure enclosure of the cable bundle1020 by the envelope 1030 is thereby ensured. Here, the first gap 120enables the first bulge 1036 to be formed in a simple manner at the sametime. In this case, the first bulge 130 can then be formed on therespective free end 100, 130 in a manner corresponding to thegeometrical configuration of the holding elements 65, 70, at least insome section or sections (cf. FIG. 11A and FIG. 12). If the holdingelements 65, 70 are of brush-type configuration, the first bulge 1036 isproduced by the fact that, during foaming, the material presses from themold cavity 40 against the lower side 105, 125 of the brushes 66, 71and, as a result, the brushes 66, 71 are bent slightly upward away fromthe mold cavity 40 (illustrated symbolically in dashed lines in FIG.11B). The indicating element 1038 corresponds to an impression of thebrushes 66, 71. If the gap 120 is arranged between the brushes 66, 71,the material of the envelope 1040 presses especially into the gap 120,with the result that the first bulge 1036, in particular, has a lateralbrush impression of the brushes 66, 71. It is also possible for theconfiguration of the indicating element 1038 as a notch 1040 to beproduced in a particularly simple manner by means of the brushes 66, 71.

In a fifth method step 3020, the cover 155 is placed on the mold 15,wherein the cover 155 blocks bending up of the holding elements 65, 70on a side facing away from the mold cavity 45. A particularly reliablegeometrical configuration of the envelope 1030, in particular of thefirst bulge 1036, is thereby ensured, even when using foaming materials.

Attention is drawn to the fact that further method steps can be providedin addition to the method steps 3000, 3005, 3010, 3015, 3020 justdescribed. It is also conceivable to dispense with some of the methodsteps 3000, 3005, 3010, 3015, 3020.

Attention is furthermore drawn to the fact that the differentconfigurations of the molds 15 and/or mold parts 16, 17 described inFIGS. 9A to 26 can be combined with one another. The features of thefastening elements 200, 400 can also be combined with one another in adifferent way. The features of the wiring harness 1010 described inFIGS. 1 to 8 can also be combined with one another.

REFERENCE SIGNS

-   10 mold system-   15 mold-   16 first mold part-   17 second mold part-   18 longitudinal end-   19 lower side of the mold part-   20 mounting board-   25 upper side of the mounting board-   26 coordinate system-   27 grid-   30 wall-   35 opening-   40 holding device-   45 mold cavity-   50 first wall section-   55 second wall section-   60 wall bottom-   61 first wall surface-   62 second wall surface-   63 wall base-   65 first holding element-   70 second holding element-   75 first contact pressure element-   80 second contact pressure element-   85 first fastening means-   86 plane of symmetry-   90 first section of the first holding element-   95 second section of the first holding element-   100 first free end of the first holding element-   105 first lower side of the first holding element-   110 third section-   115 fourth section-   120 gap-   125 second lower side-   130 second free end-   135 second fastening means-   140 pin (first engagement element)-   141 free end of the pin-   142 first socket-   145 first recess-   150 sealing element-   155 cover-   160 third fastening means-   165 upper side of the wall-   170 free end of the holding element-   175 first web-   180 second web-   185 first aperture-   190 end face of the mold part-   195 end face of the further mold part-   200 first fastening element-   205 second engagement element-   210 second socket-   215 first wall region-   220 second wall region-   225 third wall region-   230 fourth wall region-   235 widened portion-   240 second aperture-   241 common region-   245 ejector-   250 first wall base section-   255 second wall base section-   260 wall base transitional section-   300 first fastening plate-   305 first fastening bracket-   310 second fastening bracket-   311 bearing surface of the fastening bracket-   312 bearing surface of the fastening bracket-   315 lateral surface-   320 third aperture-   325 fourth aperture-   330 first insertion opening-   335 second insertion opening-   340 first bracket section-   345 second bracket section-   349 free end of the second bracket section-   350 supporting section-   355 supporting surface-   360 second gap-   400 second fastening element-   405 fastening plate-   410 first engagement section-   415 second engagement section-   420 boundary edge-   425 engagement plate-   430 structure-   1000 body-   1005 structure-   1006 holding structure-   1010 wiring harness-   1015 bearing surface-   1020 cable bundle-   1025 cable of the cable bundle-   1030 envelope-   1035 lateral surface-   1036 first bulge-   1037 upper side-   1038 indicating element-   1040 notch-   1100 first space-   1105 second space-   1110 partition wall-   1115 opening-   1120 second bulge-   1121 bulge contour-   1122 opening contour-   1200 first layer-   1205 second layer-   1210 third layer-   1215 surface structure-   1220 surface-   1225 rib structure-   1230 rib-   1235 rib recess-   1240 recess base of the rib recess-   1300 recess-   1305 recess contour-   1310 surface of the structure-   1400 first envelope section-   1405 second envelope section-   1410 transitional section-   1415 lateral surface of the first envelope section-   1420 lateral surface of the second envelope section-   1425 transitional surface-   1500 profile-   1505 first profile section-   1510 second profile section-   1600 means-   1605 first region-   1610 insertion opening-   1615 second region-   3000 first method step-   3005 second method step-   3010 third method step-   3015 fourth method step-   3020 fifth method step-   a distance-   b₁ first transverse extent-   b₂ second transverse extent

1. A wiring harness for a motor vehicle, comprising: at least one cablebundle comprising at least two cables, and an envelope, wherein at leastsome section or sections of the cable bundle is/are embedded in theenvelope.
 2. The wiring harness according to claim 1, further comprisinga first fastening element, wherein at least some section or sections ofthe first fastening element is/are embedded in the envelope, wherein thefirst fastening element is configured to hold at least one of the cablesof the cable bundle in a predefined position.
 3. The wiring harnessaccording to claim 1, further comprising a second fastening element,wherein the second fastening element has a first engagement section,which is embedded in the envelope, wherein the second fastening elementhas a second engagement section, which is configured to engage in avehicle component of the motor vehicle in order to fasten the wiringharness on the vehicle component.
 4. The wiring harness according toclaim 1, wherein the envelope has a first layer and a second layer,wherein the cable bundle is embedded in the first layer, wherein thefirst layer comprises a first material, and the second layer comprises asecond material, wherein the second material has a different elasticityfrom, preferably a higher elasticity than, the first material.
 5. Thewiring harness according to claim 4, wherein the envelope has a thirdlayer wherein the third layer is arranged on a side of the second layerwhich faces away from the first layer, wherein the third layer comprisesat least one third material, wherein the third material comprises anadhesive and/or has a third elasticity, which is different from,preferably lower than, the first and/or the second elasticity.
 6. Thewiring harness according to claim 4, wherein the first layer is ofslimmer configuration in a direction transverse to the cable bundle thanthe second layer, wherein the first layer is configured to engage in arecess in a structure of a vehicle component.
 7. The wiring harnessaccording to claim 6, wherein the first layer has a trapezoidal crosssection and the second layer has a substantially rectangular crosssection or has a rib structure.
 8. The wiring harness according to claim4, wherein, on a side facing the first layer, the second layer has asurface provided with a predefined surface structure, wherein, on a sidefacing away from the first layer, the second layer is of flatconfiguration.
 9. The wiring harness according to claim 1, wherein theenvelope has a first envelope section and a second envelope section,wherein the first envelope section has a first transverse extent (b₁)with respect to a first direction of longitudinal extent of the firstenvelope section, wherein the second envelope section has a secondtransverse extent (b₂) with respect to a second direction oflongitudinal extent of the second envelope section, wherein the firsttransverse extent (b₁) is greater than the second transverse extent(b₂).
 10. The wiring harness according to claim 9, wherein the envelopehas a transitional section, wherein the transitional section is arrangedbetween the first envelope section and the second envelope section,wherein the first envelope section has a first lateral surface and thesecond envelope section has a second lateral surface, wherein thetransitional section has a transitional surface, which has a sloperelative to the first lateral surface and the second lateral surface,wherein the slope has an angle (α₁), wherein the angle (α₁) has a valuewhich is less than 45°, in particular less than 30°, in particular lessthan 20°, in particular less than 15°, in particular less than 10°. 11.A vehicle component of a motor vehicle, comprising a wiring harnessaccording to claim 1 with a second bulge and a structure, wherein thestructure has at least one recess with a recess contour, wherein atleast the second bulge engages in the recess, wherein the second bulgeis arranged at least partially under stress, preferably undercompression, in the recess, and the second bulge presses a bulge contourof the second bulge against the recess contour and provides a frictionalconnection between the wiring harness and the vehicle component, whereinthe wiring harness is arranged in the recess.
 12. A vehicle component ofa motor vehicle according claim 11, wherein the structure has a surfaceadjoining the recess, wherein the surface of the structure and an upperside of the envelope are of stepless configuration, and the surface andthe upper side extend in a common plane.
 13. A mold for producing awiring harness according to claim 1, comprising a wall and an opening,wherein the wall delimits a mold cavity, at least laterally, wherein themold cavity adjoins the opening at the top.
 14. The mold according toclaim 13, wherein an aperture is provided in the wall, wherein theaperture is configured as a through opening and is arranged in a wallbottom of the mold, wherein the wall bottom delimits the mold cavity atthe bottom, wherein the aperture is configured to accommodate at least asection of a first and/or second fastening element of the wiringharness, and/or wherein an ejector for removing the wiring harness fromthe mold is configured to reach through the aperture.
 15. The moldaccording to claim 13, wherein the wall has a wall surface which facesthe mold cavity, wherein the wall surface is laser-polished, at least insome section or sections.
 16. The mold according to claim 15, wherein asealing element is arranged at one longitudinal end of the wall in orderat least partially to prevent emergence of the envelope from the moldcavity.
 17. The mold according to claim 15, comprising a first mold partand a second mold part, wherein the first mold part has an engagementelement at one longitudinal end, wherein the second mold part has asocket configured to correspond to the engagement element at alongitudinal end of the second mold part which faces the longitudinalend of the first mold part, wherein the engagement element engages inthe socket and connects the first mold part positively to the secondmold part, wherein the engagement element and the socket are configuredin such a way in relation to one another that removal in thelongitudinal direction is blocked by the engagement of the engagementelement in the socket, wherein the engagement element and the first moldpart are of integral and materially unitary configuration.
 18. A moldsystem comprising a mold and a mounting board, wherein the mold isconfigured according claim 13, wherein, on a side facing the mountingboard, the mold has a further engagement element and, on a side facingthe mold, the mounting board has at least one grid having a plurality offurther sockets, or wherein, on a side facing the mounting board themold has a further socket and, on a side facing the mold, the mountingboard has a grid having a plurality of further engagement elements,wherein the further engagement element and the further socket arearranged in a manner corresponding to one another, wherein the furtherengagement element engages in one of the further sockets and connectsthe mounting board positively and in a reversibly detachable manner tothe mold, wherein the other further sockets of the grid remain free orwherein one of the further engagement elements engages in the furthersocket and connects the mounting board positively and in a reversiblydetachable manner to the mold, wherein the other further engagementelements of the grid remain free, wherein the further engagement elementis preferably of integral and materially unitary configuration with themold or with the mounting board.